Virtual reality and real welding training system and method

ABSTRACT

A virtual welding station includes a virtual sequencer for simulating different welding techniques and non-welding operations. The virtual welding station can be used to train an operator on the production of complete assemblies.

RELATED APPLICATION

The present application is being filed as a non-provisional patent application claiming priority/benefit under 35 U.S.C. §119(e) from U.S. Provisional Patent Application No. 61/900,136 filed on Nov. 5, 2013, the entire disclosure of which is incorporated herein by reference.

FIELD

The present invention relates to the art of welding station simulation and more particularly to a virtual sequencer that simulates semi-automatic welding of complex assemblies.

BACKGROUND

Learning how to perform all of the steps required in a welding station, including the steps that are in addition to welding, traditionally takes many hours of instruction, training, and practice.

There are many different types of operations that can be learned, including various welding and non-welding operations. Typically, the steps of a welding station are learned by a student operator at a real welding station performing welding operations on real metal pieces. Such real-world training can tie up scarce welding resources and use up limited welding materials. Training while welding on real production parts can be costly as an operator learns the assembly operation. Training time on real production parts typically requires two operators (costly) and potentially generates scrap, rework, or low quality assemblies.

Recently, however, the idea of training using welding simulations has become more popular. Some welding simulations are implemented via personal computers, on-line via the Internet, or even as virtual welders. However, conventional welding simulations tend to be limited to single welds in their training focus and typically involve one welding technique at a time. Conventional virtual reality training generally only involves individual welds and does not prepare, or train, the operator how to produce a complete assembly that involves multiple welding and/or assembly steps. In practice, unlike in these simulators, there are many different welding techniques and non-welding operations required at a welding station that are needed to create an entire, complete welded assembly. Thus, there is an unmet need for welding simulation systems and methods that can effectively simulate the production of complete assemblies.

SUMMARY

The general inventive concepts encompass virtual welding systems (and related methods), including the illustrative systems and methods disclosed and suggested herein.

In one exemplary embodiment, a virtual welding system comprises: a logic processor based subsystem operable to execute coded instructions for generating an interactive welding environment that emulates welding activity on a virtual weld joint defined by at least one of a welding coupon and a sample part; a virtual sequence controller operatively connected to the logic processor based subsystem for implementing a virtual sequence; displaying means operatively connected to the logic processor based subsystem for visually depicting the interactive welding environment including the virtual weld joint; an input device for performing virtual welding activity on the virtual weld joint in real time; and a spatial tracker comprising one or more sensors adapted to track movement of the input device in real time for communicating data about the movement of the input device to the logic processor based subsystem.

In one exemplary embodiment, the virtual welding system further comprises a user interface for a user to provide input to the virtual welding system.

In one exemplary embodiment, the logic processor based subsystem is housed within a simulated welding console that is sized and shaped to approximate a welding power source.

In one exemplary embodiment, the logic processor based subsystem implements the virtual sequence controller.

In one exemplary embodiment, the virtual sequence controller comprises a microprocessor, a sequence control program, and a memory. The memory stores one or more state table files.

In one exemplary embodiment, the virtual welding system further comprises a virtual sequence configuration tool. The virtual sequence configuration tool allows a user to modify one of the existing state table files. The virtual sequence configuration tool allows a user to create a new state table file, for storing in the memory.

In one exemplary embodiment, the virtual sequence is defined by at least one of the state table files.

In one exemplary embodiment, a user selects one of the state table files based on a task to be performed. In one exemplary embodiment, the task is production of a complete virtual assembly.

In one exemplary embodiment, the virtual sequence includes a plurality of operations to be performed in order, each operation intended to achieve a particular state.

In one exemplary embodiment, at least one of the operations is a manual operation to be performed by the user. In one exemplary embodiment, the manual operation is one of providing user information, retrieving a part, providing part information, placing a part, securing a part, and providing assembly information.

In one exemplary embodiment, the virtual welding system further comprises a virtual sequence display means. The virtual sequence display means displays information on the manual operation.

In one exemplary embodiment, at least one of the operations is an automatic operation to be performed by the virtual welding system. In one exemplary embodiment, the automatic operation is one of specifying a weld process, specifying a gas type, specifying a gas flow rate, specifying a stick electrode type, specifying a flux cored wire type, specifying a wire feed speed, specifying a voltage level, specifying an amperage, specifying a polarity, and specifying a background environment for the interactive welding environment.

In one exemplary embodiment, at least one of the operations is a manual operation to be performed by the user; and at least one of the operations is an automatic operation to be performed by the virtual welding system.

In one exemplary embodiment, each state is associated with a condition. In one exemplary embodiment, the sequence controller performs an action if the condition is not met. In one exemplary embodiment, the action is waiting a predetermined duration. In one exemplary embodiment, the action is repeating the operation for the state. In one exemplary embodiment, the action is restarting the virtual sequence.

In one exemplary embodiment, the virtual sequence includes a simulated function selected from the group consisting of: a Quality Check function, a Repeat function, a Notify Welder function, an Enter Job function, a Job Report function, a System Check function, a Perform Welding Operation function, and combinations thereof.

In one exemplary embodiment, the displaying means comprises an LCD screen.

In one exemplary embodiment, the displaying means is a face-mounted display. In one exemplary embodiment, the face-mounted display is integrated in a welding helmet. In one exemplary embodiment, the welding helmet includes at least one speaker.

In one exemplary embodiment, the displaying means comprises a first display and a second display. The first display is a face-mounted display, while the second display is not a face-mounted display.

In one exemplary embodiment, the first display and the second display are operable to present different views of the interactive welding environment (at the same time).

In one exemplary embodiment, the displaying means is operable to communicate over a network. In one exemplary embodiment, the network is a wireless network.

In one exemplary embodiment, the input device is a mock welding tool.

In one exemplary embodiment, the input device is operable to communicate over a network. In one exemplary embodiment, the network is a wireless network.

In one exemplary embodiment, the spatial tracker generates a magnetic field. The spatial tracker is operable to determine the location of the one or more sensors within the magnetic field.

In one exemplary embodiment, the virtual welding system further comprises a support structure.

In one exemplary embodiment, the support structure is a stand. In one exemplary embodiment, the stand comprises a base, a vertical post, an adjustable table, and an adjustable arm. In one exemplary embodiment, the welding coupon is operable to be attached to the stand. In one exemplary embodiment, at least one clamp is used to attach the welding coupon to the stand.

In one exemplary embodiment, the support structure is an assembly fixture. In one exemplary embodiment, the assembly fixture holds the sample part.

In one exemplary embodiment, the virtual welding system further comprises means for collecting and storing welding and operational data from the virtual sequence controller.

In one exemplary embodiment, the virtual welding system further comprises means for assigning a quality score to the virtual welding activity.

BRIEF DESCRIPTION OF THE DRAWINGS

In the accompanying drawings, which are incorporated in and constitute a part of the specification, various exemplary embodiments of the invention are illustrated, which, together with a general summary of the invention given above and the detailed description given below, serve to exemplify embodiments of this invention.

FIG. 1 is a block diagram that illustrates a system providing arc welding training in a real-time virtual reality environment, according to an exemplary embodiment;

FIG. 2 is a block diagram that illustrates a simulated welding console and observer display device (ODD) of the system of FIG. 1, according to an exemplary embodiment;

FIG. 3 is a diagram that illustrates a simulated welding console and sequencer display/user interface (SDUI) of the system of FIG. 1, according to an exemplary embodiment;

FIG. 4 is a diagram that illustrates a table/stand (T/S) of the system of FIG. 1, according to an exemplary embodiment;

FIG. 5 is a drawing that illustrates a sample part (weldment) in an assembly fixture of the system of FIG. 1, according to an exemplary embodiment;

FIG. 6 is a drawing that illustrates various elements of the spatial tracker (ST) of FIG. 1, according to an exemplary embodiment;

FIG. 7 is a block diagram that further illustrates the system of FIG. 1, according to an exemplary embodiment;

FIG. 8 is a flow chart that illustrates sequencer logic, according to an exemplary embodiment;

FIG. 9 is a system diagram that illustrates a virtual system with a reprogrammable virtual sequencer controller, according to an exemplary embodiment;

FIG. 10 is a schematic diagram that further illustrates the exemplary reprogrammable virtual sequencer controller of FIG. 9;

FIG. 11 is a flow chart that illustrates conditional checks in the exemplary virtual sequence controller of FIGS. 9 and 10;

FIG. 12 is a flow chart that illustrates operation of a sequence control program in the exemplary virtual sequencer controller of FIGS. 9 and 10;

FIG. 13 is a flow diagram that illustrates exemplary operations included in a virtual sequence utilizing a semi-automatic welding work cell, according to an exemplary embodiment;

FIG. 14 is a flow chart that illustrates a training routine, according to an exemplary embodiment;

FIG. 15 is a flow chart that illustrates a training routine using a virtual score, according to an exemplary embodiment;

FIG. 16 is a flow chart that illustrates a hiring process using a virtual performance measure, according to an exemplary embodiment;

FIG. 17 is a flow chart that illustrates an optimization routine using a virtual weld station, according to an exemplary embodiment;

FIG. 18 is a flow chart that illustrates a training routine using a virtual score and a real-world score, according to an exemplary embodiment;

FIG. 19 is a flow chart that illustrates a training routine using a virtual score and a real-world score, according to an exemplary embodiment; and

FIG. 20 is a flow chart that illustrates a routine using a virtual score and a real-world score to determine how well the virtual station predicts real-world performance, according to an exemplary embodiment.

DETAILED DESCRIPTION

In an exemplary embodiment, a virtual (simulated) weld station includes a virtual welding job sequencer. The virtual welding job sequencer simulates a real-world welding job sequencer (e.g., Lincoln Electric's Weld Sequencer) in a virtual environment or using one or more virtual components, such as a virtual welder. A real-world welding job sequencer can control the operations of a semi-automatic work cell, including instructing the operator on what to do next and automatically changing certain parameters of the welding cell, including, for example, welding parameters. The real-world welding job sequencer can provide the operator with an array of commands and instructions that relate to welding and non-welding aspects of the operations associated with the welding station.

A virtual welding station, including the virtual sequencer, can include Lincoln Electric's VRTEX® (virtual reality arc welding training machine) and Weld Sequencer technologies integrated into the virtual welding station to create a unique training/testing environment. In the virtual welding station, a welding sequence is used with the VRTEX system for virtual reality training to produce a given assembly. This requires a series of virtual welds on a virtual assembly, which trains the operator on the welding processes, operations, and procedures required to produce a real assembly (individual welds plus complete work instructions). Once the virtual training has been completed, an operator will be prepared for the real-world welding processes and the sequence of events required to create a real assembly. After training with the Virtual Sequencer, the operator now uses the Weld Sequencer to produce real assemblies, and the same welding sequence is repeated. Real welding operations are controlled and monitored by the Weld Sequencer while WeldScore is used to monitor the welding processes. The WeldScore monitor includes, but is not limited to, the embodiments disclosed in U.S. Ser. No. 12/775,729 filed May 7, 2010, now U.S. Pat. No. 8,569,646, which is incorporated herein by reference in its entirety.

In an exemplary embodiment, all training data (from VRTEX and Weld Sequencer) is collected in a production monitoring system. Comprehensive lesson plans (with virtual assembly creation and real assembly creation) are supplied with this technology. This includes a common welding sequence that is used in the virtual (VRTEX) environment and the real Weld Sequencer controller along with a kit of parts for the real welding portion of the training. The final outcome of an individual lesson is a complete report of all training welds/operations, assembly cycle time, and a real part from the kit.

The operational sequence (used in both the virtual and real-world environments) can contain validation checks on parameters like part placement, travel speed (welding duration), average amperage, and other welding variables. Use of these common requirements reinforces the real requirements that are first learned in the virtual weld station and then repeated on real assemblies (while the Virtual Sequencer and Weld Sequencer direct and monitor the operations in the same manner, respectively).

Successful completion of the virtual training may include an overall score for all welding operations, total cycle time limits, total arc time limits, number of arc starts/stops, and other welding variables. Once minimum requirements are achieved (e.g., once a performance score reaches a predetermined threshold), an operator would be approved for the next training step involving real welding.

During real welding, the Weld Sequencer will use the same welding sequence with the same requirements as the Virtual Sequencer for successfully completing a real assembly.

Welding and operational data from the Virtual Sequencer and Weld Sequencer operations can be collected in a common production monitoring system (e.g., CheckPoint). Data can be summarized by operator, welding operations (virtual and real), number of assemblies created, quality scores, cycle time metrics, etc.

In an exemplary embodiment, as with a real-world sequencer, a virtual sequencer can automatically select and implement functions of a virtual welding work cell. For example, a function could include a particular virtual weld schedule to be used within the virtual work cell. In other words, the virtual sequencer can select a virtual weld schedule to be used for a particular virtual weld, and modify the settings of the virtual work cell in accordance with the selected virtual weld schedule, automatically for the operator (i.e., without the operator's specific intervention).

Additionally, in the exemplary embodiment, the virtual sequencer may automatically indicate a sequence of operations, steps or different welds that the operator should follow to create a final virtual assembly. In conjunction with the automatic selection of virtual welding schedules, this indicated sequence allows an operator to follow the sequence to create a final virtual assembly, just like the operator would be expected to do in the real world weld station.

Accordingly, since the virtual sequencer sets up the virtual welding equipment and organizes the workflow, just like a real-world sequencer, the virtual sequencer can be used to train operators before they begin to operate in a real-world welding cell or station. In this manner, the chance for error in the real-world welding station is greatly reduced and productivity and quality are improved.

In an exemplary embodiment, a virtual reality welding station (VRWS) comprises a programmable processor-based subsystem, a spatial tracker operatively connected to the programmable processor-based subsystem, at least one mock welding tool capable of being spatially tracked by the spatial tracker, and at least one display device operatively connected to the programmable processor-based subsystem. The VRWS is capable of simulating, in a virtual reality space, operations associated with a real-world welding station. The operations can include various different types of welds and non-welding operations. For welding operations, the VRWS is capable of displaying the simulated weld puddle on the display device in real-time. As used herein, the term “real-time” means perceiving and experiencing in time in a simulated environment in the same way that a user would perceive and experience in a real-world welding scenario. For non-welding operations, such as, for example, operator identification entering/scanning, part identification entering/scanning, part fixturing, fixture manipulation/control, inspections, etc., the system is capable of replicating and/or simulating the steps that the operator needs to complete for the welding operation at a particular welding station. Generally, the VRWS may include any or all of the features and capabilities disclosed in the following patent applications, each of which is incorporated herein by reference in its entirety: U.S. Ser. No. 11/227,349 filed Sep. 15, 2005, now U.S. Pat. No. 8,692,157; U.S. Ser. No. 11/613,652 filed Dec. 20, 2006; U.S. Ser. No. 12/501,257 filed Jul. 10, 2009, now U.S. Pat. No. 8,747,116; U.S. Ser. No. 12/501,263 filed Jul. 10, 2009; U.S. Ser. No. 12/504,870 filed Jul. 17, 2009; U.S. Ser. No. 12/719,053 filed Mar. 8, 2010, now U.S. Pat. No. 8,274,013; U.S. Ser. No. 13/081,725 filed Apr. 7, 2011, now U.S. Pat. No. 8,657,605; U.S. Ser. No. 13/364,489 filed Feb. 2, 2012; U.S. Ser. No. 13/720,300 filed Dec. 19, 2012, now U.S. Pat. No. 8,787,051; U.S. Ser. No. 13/792,288 filed Mar. 11, 2013, now U.S. Pat. No. 8,834,168; U.S. Ser. No. 13/792,309 filed Mar. 11, 2013; U.S. Ser. No. 13/792,294 filed Mar. 11, 2013, now U.S. Pat. No. 8,851,896; U.S. Ser. No. 13/792,280 filed Mar. 11, 2013; and U.S. Ser. No. 13/545,058 filed Jul. 10, 2012.

Referring now to the drawings, which are provided for the purpose of illustrating the various exemplary embodiments disclosed or otherwise suggested herein and not for the purpose of limiting same, FIG. 1 illustrates an exemplary embodiment of a system block diagram of a system 100 for providing welding station training in a real-time virtual reality environment. The system 100 includes a programmable processor-based subsystem (PPS) 110. The system 100 further includes a spatial tracker (ST) 120 operatively connected to the PPS 110. The system 100 also includes a physical welding user interface (WUI) 130 operatively connected to the PPS 110 and a face-mounted display device (FMDD) 140 operatively connected to the PPS 110 and the ST 120. The system 100 may also include an observer display device (ODD) 150 operatively connected to the PPS 110. The system 100 also includes at least one mock welding tool (MWT) 160 operatively connected to the ST 120 and the PPS 110. The system 100 may include a table/stand (T/S) 170. The system 100 may also include at least one welding coupon (WC) 180 capable of being attached to the T/S 170. The system 100 may include an assembly fixture (AF) 182. The system 100 may also include at least one sample part (SP) 184. The system 100 also includes a virtual sequencer (VS) 186 and a sequencer display/user interface (SDUI) 188. In other exemplary embodiments, the VS 186 may be combined with the PPS 110 and/or the SDUI 188 may be combined with the WUI 130 and/or other interfaces, displays, etc., to simulate the number and type of interfaces and/or displays that the station operator will be required to interact with in the real-world welding station.

The system 100 may also include various other devices, such as, for example, operational devices 190, that simulate the real-world welding station devices needed for certain operations. As shown in FIG. 1, an operational device 190 may be associated with the AF 182, for example, to verify SP 184 placement within the AF 182, manipulate the position of the AF 182, actuate one or more clamps to hold the SP 184 in the AF 182, etc. Other devices (not shown) may include, for example, scanners, readers, user interfaces, displays (including, e.g., configurable visual aids), visual/audible indicators (e.g., for sequence error, weld out-of-limits, WeldScore defect detection), PLC interfaces, interlocks (e.g., preheat and/or interpass temperature, position of automatic positioners, part detection/part loaded, clamps closed/open), control panels, assembly tools, inspection tools, operator position sensors (e.g., weight-sensing mat), part position/proximity sensors, safety/lock-out devices, lighting control, material handling devices, part and/or assembly gauges (e.g., for quality control), etc. In accordance with other exemplary embodiments, a mock gas bottle is provided (not shown) simulating a source of shielding gas and having an adjustable flow regulator. Some of the above elements of the system 100 may be real-world components that are used in the virtual weld station. For example, a real-world assembly fixture 182 may be used to hold the sample part 184. Any combination of virtual and real-world components may comprise the virtual weld station.

FIG. 2 illustrates an exemplary embodiment of a simulated welding console 135 (simulating a welding power source user interface) with an observer display device (ODD) 150 of the system 100 of FIG. 1. The physical WUI 130 resides on a front portion of the console 135 and provides knobs, buttons, and a joystick for user selection of various modes and functions. The optional ODD 150 is attached to a top portion of the console 135. The MWT 160 rests in a holder attached to a side portion of the console 135. Internally, the console 135 can hold, or otherwise house, various components of the system 100, for example, the PPS 110, VS 186, and/or a portion of the ST 120.

FIG. 3 illustrates an exemplary embodiment of a simulated welding console 135 (simulating a welding power source user interface) and a SDUI 188 of the system 100 of FIG. 1. A zoomed-in view of an exemplary screenshot 189 of the SDUI 188 is also shown. The physical SDUI 188 can provide a display screen, knobs, buttons, and/or a joystick for user selection of various modes and functions. The VS 186 may be integrated with the SDUI 188 or may be included with the PPS 110, which may be included in the console 135.

FIG. 4 illustrates an exemplary embodiment of a table/stand (T/S) 170 of the system 100 of FIG. 1. The T/S 170 includes an adjustable table 171, a stand or base 172, an adjustable arm 173, and a vertical post 174. The table 171, the stand 172, and the 173 are each attached to the vertical post 174. The table 171 and the arm 173 are each capable of being manually adjusted upward, downward, and rotationally with respect to the vertical post 174. The arm 173 is used to hold various welding coupons (e.g., welding coupon 175) and/or sample parts 184, and a user may rest his/her arm on the table 171 when training. The vertical post 174 is indexed with position information such that a user may know exactly where the arm 173 and the table 171 are vertically positioned on the post 174. This vertical position information may be entered into the system by a user using the WUI 130, the ODD 150, and/or the SDUI 188.

FIG. 5 illustrates an exemplary assembly fixture (AF) 182, shown as a single adjustable support structure. The support structure is depicted holding (i.e., supporting) a sample part (SP) 184, i.e., a weldment having spaced rails 514, 516. The support structure 182 includes an upper movable platform 518, on which is held a top surface 520 of the weldment 184. Movable platform 518 is adjusted to a desired position or orientation, for a particular area of the weldment 184 for simulated welding. The weldment 184 is boxed around frame 522 by elongated strips 524 (only short pieces of which are shown in FIG. 5). Top surface 520 of weldment 184 is the upper side of the rail section when incorporated into the rail system. Brace structures 526 are at spaced positions along the length of weldment 184. As illustrated in this figure, brace structures 526 are positioned to have rails 514, 516 positioned between the braces 526 and outer portions of frame 522 of weldment 184. With further attention to the support structure 182, a lower fixed support base 528 is in operable connection with movable upper platform 518 through transversely spaced multi-positionable hinges 530, 532. In one embodiment, the multi-positionable hinges may be 2-bar linkages, and the following discussion primarily refers to components or elements 530, 532 as 2-bar linkages. It is, however, to be appreciated that other hinges or other appropriate structures which permit suitable movement of movable platform 518 may be used without departing from the scope and intent of the general inventive concepts. The moveable platform 518 may be controlled by an operational device 190 from the system 100 of FIG. 1. In addition, the support structure 182 (as the AF) and the weldment 184 (as the SP), as depicted in FIG. 5, are merely exemplary. The AF 182 and the SP 184 may consist of any shape, construction, number of parts, type of parts, and size of parts as required for any welding operation.

As mentioned, the support structure 182 may be adjusted to locate the weldment 184 to an orientation or position appropriate for a desired simulated welding operation. To adjust the position of movable upper platform 518 with respect to fixed support base 528, actuators, such as length adjusting members 550, 552, are connected between pintles or pivot elements 540, 542 and pintles or pivot elements 554 and 556, respectively, the latter of which are positioned generally near the center of fixed base 528. In addition, an actuator, such as length adjusting member 560, is connected between fixed support base 528 via pintle or pivot element 556 and pintle or pivot element 562 to movable platform 518. Positioning of length adjusting members 550, 552, and 560 determine the position of movable platform 518 and therefore the location of weldment 184 being carried thereon. Pivot elements 530 c, 532 c, 530 d, 532 d, 540, 542, 554, 556, and 562 provide the support structure 182 with 3-degrees of freedom, i.e., capable of moving in the x and z directions, as well as tilting in the x-z plane. The physical size and operational characteristics of the individual length adjusting members 550, 552, 560 act to determine the envelope of motion for the support structure 182. While in one exemplary embodiment, the length adjusting members are hydraulic actuators, they may also represent other actuators such as pneumatic, ball-and-screw actuators, and/or any type of electrically controlled actuators. Any or all of these movable components may be controlled by one or more operational devices 190 from the system 100 of FIG. 1.

Other exemplary embodiments may include any combination of one or more of tables 171, arms 173, assembly fixtures 182, coupons 180, and/or sample parts 184 to best simulate the real-world weld station operations being simulated.

In accordance with other exemplary embodiments, the positions of the table 171, the arm 173, and/or the AF 182 may be automatically set by the PSS 110 and/or the VS 186 via preprogrammed settings, or via the WUI 130, the ODD 150, and/or the SDUI 188 as commanded by a user. In such embodiments, the T/S 170 and/or AF 182 typically includes, for example, motors and/or servo-mechanisms, and signal commands from the devices mentioned above activate the motors and/or servo-mechanisms.

In accordance with further exemplary embodiments, the positions of the table 171, the arm 173, the AF 182, the WC 180, and/or the SP 184 are detected by the system 100. In this way, a user does not have to manually input the position information via a user interface. In such embodiments, the T/S 170 and/or the AF 182 include position and orientation detectors and send signal commands to the PPS 110 and/or the VS 186 to provide position and orientation information. The WC 175 and/or the SP 184 may include position detecting sensors (e.g., coiled sensors for detecting magnetic fields). A user is able to see a rendering of the T/S 170 and/or the AF 182 on the ODD 150, the FMDD 140, and/or the SDUI 188 as the adjustment parameters are changed, in accordance with an exemplary embodiment.

In accordance with further exemplary embodiments, the positions of the table 171, the arm 173, the AF 182, the WC 180, and/or the SP 184 are dictated and monitored by the system 100. In various exemplary embodiments, positions of the table 171, the arm 173, the AF 182, the WC 180, and/or the SP 184 may be controlled by operational devices 190 based on commands from the PPS 110 and/or the VS 186. In other exemplary embodiments, a user may be provided with the position information via a user interface and manually position the table 171, the arm 173, the AF 182, the WC 180, and/or the SP 184. Automatic and manual positioning determinations are made based on the real-world weld station operations being simulated.

Various other operational devices 190 may be included in the VRWS in order to simulate the real-world welding station. Control and communication with these devices is designed to mimic the real-world welding environment, using virtual and/or real-world devices and components, similar to the exemplary AF 182 described herein.

FIG. 6 illustrates various elements of an exemplary embodiment of the spatial tracker (ST) 120 of FIG. 1. The ST 120 is a magnetic tracker that is capable of operatively interfacing with the PPS 110 of the system 100. The ST 120 includes a magnetic source 121 and source cable, at least one sensor 122 and associated cable, host software on disk 123, a power source 124 and associated cable, USB and RS-232 cables 125, and a processor tracking unit 126. The magnetic source 121 is capable of being operatively connected to, or otherwise interfaced with, the processor tracking unit 126 (e.g., via a cable). The sensor 122 is capable of being operatively connected to, or otherwise interfaced with, the processor tracking unit 126 (e.g., via a cable). The power source 124 is capable of being operatively connected to, or otherwise interfaced with, the processor tracking unit 126 (e.g., via a cable). The processor tracking unit 126 is capable of being operatively connected to, or otherwise interfaced with, the PPS 110 via a USB or RS-232 cable 125. The host software on disk 123 is capable of being loaded onto the PPS 110 and allows functional communication between the ST 120 and the PPS 110.

As shown in FIG. 4, the magnetic source 121 of the ST 120 is mounted on, or otherwise interfaced with, a first portion of the arm 173. Referring to FIG. 5, the magnetic source 121 of the ST 120 is mounted on, or otherwise interfaced with, the back portion of the upper platform 18. In other exemplary embodiments, multiple magnetic sources 121 are mounted in various locations and may be used to provide proper tracking. The magnetic source 121 creates a magnetic field around the magnetic source 121, including the space encompassing the WC 175 and/or the SP 184, which establishes a 3D spatial frame of reference. The T/S 170 and/or the assembly fixture 182 may be largely non-metallic (non-ferric and non-conductive) so as not to distort the magnetic field created by the magnetic source 121. The sensor 122 can include three induction coils orthogonally aligned along three spatial directions. The induction coils of the sensor 122 can each measure the strength of the magnetic field in each of the three directions and provide that information to the processor tracking unit 126. As a result, the system 100 is able to know where any portion of the WC 175 and/or the SP 184 is with respect to the 3D spatial frame of reference established by the magnetic field. The sensor 122 may be attached to the MWT 160 or the FMDD 140, allowing the MWT 160 or the FMDD 140 to be tracked by the ST 120 with respect to the 3D spatial frame of reference in both space and orientation. When two sensors 122 are provided and operatively connected to the processor tracking unit 126, both the MWT 160 and the FMDD 140 may be tracked. In this manner, the system 100 is capable of creating a virtual WC, a virtual SP, a virtual MWT, a virtual T/S, and/or a virtual AF in virtual reality space and displaying the virtual WC, the virtual SP, the virtual MWT, the virtual T/S, and/or the virtual AF on the FMDD 140, the ODD 150, and/or the SDUI 188 as the MWT 160 and the FMDD 140 are tracked with respect to the 3D spatial frame of reference.

In accordance with another exemplary embodiment, the sensor(s) 122 may wirelessly interface to the processor tracking unit 126, and the processor tracking unit 126 may wirelessly interface to the PPS 110. In accordance with other exemplary embodiments, other types of spatial trackers 120 may be used in the system 100 including, for example, an accelerometer/gyroscope-based tracker, an optical tracker (active or passive), an infrared tracker, an acoustic tracker, a laser tracker, a radio frequency tracker, an inertial tracker, and augmented reality based tracking systems. Other types of trackers may be possible as well. In some exemplary embodiments, a combination of two or more different tracking technologies can be employed.

FIG. 7 illustrates an exemplary embodiment of the system 100 of FIG. 1. The various functional blocks of the system 100 as shown in FIG. 7 are implemented largely via software instructions and modules running on the PPS 110 and/or the VS 186. The various functional blocks of the system 100 include a physical interface 701, torch and clamp models 702, environment models 703, sound content functionality 704, welding sounds 705, assembly fixture/stand/table model 706, internal architecture functionality 707, calibration functionality 708, operational device models 709, sample part/coupon models 710, welding physics 711, internal physics adjustment tool (tweaker) 712, graphical user interface functionality 713, graphing functionality 714, student reports functionality 715, renderer 716, bead rendering 717, 3D textures 718, visual cues functionality 719, scoring and tolerance functionality 720, tolerance editor 721, special effects 722, and sequence models 723.

The functionality of the various blocks shown in FIG. 7 operates similarly to the functionality disclosed in U.S. Ser. No. 12/501,257, which, as noted above, is incorporated herein by reference in its entirety. Modeling of the AF 182 may be similar to the T/S 170 in block 706. Modeling of the SP 184 may be similar to the WC 180 in block 710. The graphical user interface functionality 713 may also include the SDUI 188 to set up/display the operations and steps of a simulated weld station scenario. In accordance with an exemplary embodiment, the set up of a welding scenario includes selecting a language, entering a user name, and selecting a weld station to simulate. In accordance with the selected weld station, the VS 186 can select the appropriate sequence models from block 723. The sequence models 723 will include the various aspects associated with the selected weld station's operations, specifying the process steps, including, for example, specifying the WC 180 and/or the SP 184; specifying the T/S 170 configuration and/or the AF 182; specifying one or more welding processes (e.g., FCAW, GMAW, SMAW) and associated axial spray, pulse, or short arc methods; specifying a gas type and flow rate; specifying a type of stick electrode; specifying a type of flux cored wire (e.g., self-shielded, gas-shielded); specifying an environment (e.g., a background environment in virtual reality space); specifying a wire feed speed; specifying a voltage level; specifying an amperage; specifying a polarity; and turning particular visual cues on or off. In other exemplary embodiments, the user may be prompted to specify certain options and/or parameters in accordance with the decisions an operator will have to specify in the real-world weld station processes that are being simulated.

The system 100 is capable of analyzing and displaying the results of virtual weld station activity. By analyzing the results, it is meant that the system 100 is capable of determining when, during the specified process steps, including welding and non-welding operations, the user has deviated from the acceptable limits of the specified processes. A score may be attributed to the user's performance. In one exemplary embodiment, the score may be a function of missed operations; improperly fixtured parts; and deviation in position, orientation, and speed of the mock welding tool 160 through ranges of tolerances, which may extend from an ideal welding pass to marginal or unacceptable welding activity, missed quality checks, or any other operations associated with the selected weld station.

Visual cues functionality 719 can provide immediate feedback to the user by displaying overlaid colors and indicators on the FMDD 140, the ODD 150, and/or the SDUI 188. Visual cues may be provided for each, or portions of each, of the operations associated with the selected weld station.

FIG. 8 is a flow diagram of sequencer logic, according to an exemplary embodiment. In this exemplary embodiment, the virtual sequencer can instruct the operator to perform any number of operations to simulate the real-world weld station. For example, the virtual sequencer can instruct the operator to perform operation 1 to achieve a particular state. Completion of operation 1 may also be associated with a condition check. If the condition is not met (e.g., part number not entered, part not placed in fixture, weld duration not long enough, etc.), the sequence may take an action, such as, for example, waiting, re-instructing, stopping, or any other action. These actions may be designed to mimic the desired action in the real-world weld station or may deviate from the real-world weld station to provide a better training experience for the operator (e.g., re-instruction). The sequence is complete when all of the operations are completed (and associated conditions are met) for the virtual weld station.

FIGS. 9-12 describe a control system, according to an exemplary embodiment. Referring now to FIGS. 9-11, an exemplary control system 902 for system 100 of FIG. 1 is shown. In various embodiments, the control system 902 may be embodied in the PPS 110, the VS 186, the simulated welding console 135, and/or other components. The system 902 includes a plurality of welding system components 950, which are typically virtual components, including a power source 951, a wire feeder 952, a travel carriage 953, a gas solenoid 954, a coolant solenoid 955, a fume extraction system 956, and a robot or programmable logic controller (PLC) 957, where the illustrated system components 950 are merely examples, and a system may be provided with more or fewer components in accordance with the general inventive concepts. The virtual welding components may be included in a simulated welding console 135, as shown in FIG. 2. Real-world welding or non-welding components may be used in the virtual weld station if certain components cannot be simulated adequately.

As shown in FIG. 10, system 902 further comprises a virtual sequencer controller 910 with a microprocessor 912, a sequence control program 922, and one or more state table files 924, 926, 928, where the virtual sequencer controller 910 also provides various interfaces including a network interface 914 for operatively coupling the sequencer 910 with a network 930, one or more dedicated communications interfaces 916 providing direct communications connectivity with one or more of the system components 950 via cables 940, as well as a user interface 918 (such as, e.g., the SDUI 188 from FIG. 1) that provides operator or user access to the sequencer 910 for setting parameters, values, etc., and/or for rendering operational information to a user.

As shown in FIG. 8, the network 930 may couple one or more of the system components 950 and the controller 910 with one another and may also provide for data sharing and other information exchange between any of the components 910, 950, and external devices or other networks (not shown). This includes connecting to the same network as real-world weld stations.

Alternatively or in combination, moreover, dedicated cabling 940 may be used to interconnect the sequencer 910 with some or all of the welding system components 950, such as power source control cable 941, wire feeder cable 942, travel carriage cable 943, gas control cable 944, coolant solenoid control cable 945, fume extractor control cable 946, and/or a robot or PLC cable 947, wherein the interfacing via the network 930 (and the network interface 914) and/or the cables 940 (and the interfaces 916) provides for exchange of data or other information, signaling, messages, etc., by which sequence control inputs 921 can be obtained from one or more system components 950 and sequence control outputs 923 can be provided to one or more of the components 950.

In one exemplary implementation, the processor 912 is a microprocessor, microcontroller, DSP, programmable logic device, etc., although any form of computational processing component may be employed within the scope of the general inventive concepts, whether hardware, software, firmware, or combinations thereof, and which may be a single device or may be implemented in multiple components. It is further noted that the controller 910 may be integrated into one of the system components 950, such as the power source 951, the wire feeder 952, etc., wherein the user interface 918 may include one or more display devices, user control knobs, switches, keypads, etc., and may interface a user with aspects of the system component 950 as well as those of the sequencer controller 910. The controller 910, moreover, includes a memory 920, which may be any suitable data store, integrated or distributed, which is operatively coupled with the processor 912 to allow access by the processor 912 to files, programs, instructions, routines, data, etc. stored in the memory 920. It is noted that while the processing component 912 and the memory 920 may be integrated in one component, such as a unitary circuit board, these elements may be separately provided or distributed across multiple system components to provide a controller 910 within the scope of the general inventive concepts. The memory 920 stores the sequence control program 922 and the state table files 924, 926, 928 providing access thereto by the processor 912. The memory 920 may also include a sequence configuration tool 929, such as a software program that may also be executed by the processor 912. States may be used to define various stages of the assembly process, including semi-automatic or manual states expected at the end of individual operations (e.g., part in fixture, weld time, etc.) and/or automatic states occurring during an operation that are automatically controlled (e.g., changes in the welding parameters that occur during a single weld).

In an exemplary embodiment, the exemplary power source 951 and other components are state table based, wherein certain of the controller outputs 923 are provided as inputs 996 to the components. In operation, controller 910 provides a desired output level or levels as one or more controller outputs 923 and to the various virtual components, which employ the output level(s) to define and regulate the desired state of the component. For example, the controller 910 may regulate a particular welding state, a particular fixture state, etc. The microprocessor 912 executes a standard routine in accordance with the sequence control program, which simulates all of the operations (and their associated parameters) associated with the specified weld station. The controller can read each state, regulating the instruction(s) associated with the current state, and determining whether a series of conditional checks is true and if so, branching to the next state (or operation).

In some exemplary embodiments, certain checks can be made to ensure that the sequence is ready to advance to the next operation. FIG. 11 illustrates the operation of an exemplary control program 962 including conditional checks, wherein a first state table and data table are loaded at 1150 and input values are obtained at 1152. Parameters are calculated and state instructions are executed at 1154, whereafter a first conditional check is loaded at 1156 and tested (e.g., TRUE or FALSE) at 1158. If the first condition is true (YES at 1158), the program 962 executes the associated instruction at 1160, updates timers at 1162, and jumps to the corresponding next state at 1164, after which the outputs are updated at 1166, and the program 962 returns to 1152. If the first tested condition is not true (NO at 1158), a determination is made at 1170 as to whether more checks are specified for the current state, and if so (YES at 1170), the next conditional check is loaded at 1172, and the program tests the new condition at 1158 as described above. Once all conditional checks have been found untrue for the current state (NO at 1170), the program 962 updates the timers at 1174, updates the outputs at 1166, and then returns again to 1152 as described above.

Referring to FIG. 12, the processor 912 executes an exemplary virtual sequence control program 922 according to the sequence controller inputs 921 and according to a selected sequence control state table file 924, 926, 928 to provide the sequence controller outputs 923 to perform a virtual operation by implementing the designated functions or instructions in state-by-state (or step-by-step) fashion, where the condition checks provide for branching to an appropriate next state based on the inputs, timers, etc. In operation, a user selects from the available state table files 924, 926, 928 (e.g., a virtual weld station sequence), using a selection feature on the sequencer user interface 918. Execution of the sequence control program 922 begins at 1202 in FIG. 12, where the processing component 912 obtains a current sequence control state table file entry at 1204 from the sequence control state table file 924, and obtains current sequence controller inputs 921 from at least one of the virtual system components at 1206. At 1208, the processor 912 executes one or more executable instructions or routines of the control program 922 identified by the instruction identifier(s) of the current entry using one or more instruction parameters thereof and provides the sequence controller outputs 923 at 1210. The virtual system condition(s) identified by one or more exit condition identifiers of the state table file entry are checked at 1212 and a determination is made at 1214 as to whether any identified exit conditions are satisfied according to the current sequence controller inputs 921, including any timers associated with the current state. If not, the current state is continued (NO at 1214), and the program execution returns to 1206-1212 as described above. In this manner, the sequence controller 910 implements a state of a given virtual sequence according to the state definition in the corresponding table file entry until one or more of the specified exit conditions have been met. Once an exit condition is satisfied (YES at 1214), the processor 912 obtains the next sequence control state table file entry at 1216 that corresponds to the satisfied exit condition identifier. Also, instructions or routines corresponding to any specified action identifiers for the satisfied condition are executed at 1216. Execution of the control program 922 then returns to obtain the current system inputs 921 at 1206 to execute the instructions identified in the new state table file entry and generate corresponding outputs 923 at 1208 and 1210, respectively, and to check the new state exit conditions at 1212 and 1214 as described above.

It is noted that the sequence control program 922 is fairly generic with respect to interoperation with the selected state table file 924, wherein the hard coded instructions and routines of program 922 are those appropriate to interface with and control the various system components and to obtain inputs therefrom, whereas the specific logic of a given virtual sequence is provided by the state table file entries and the elements thereof. In this manner, the embodiments essentially decouple the virtual sequence logic in the table files 924, 926, 928 from the hard coded executable instructions and routines of the control program 922. Consequently, reconfiguration of an entire virtual system can be accomplished without recompiling and installing software or firmware and without hardware modification (e.g., no need to modify or recompile the sequence control program 922). Instead, a state table file 924, 926, 928 can be constructed and simply stored in memory 920 (or in any suitable data store accessible by the processing component 912) in order to implement a new virtual operational sequence. Furthermore, existing state table files 924, 926, 928 can be used as a starting point or template, with state table file entries being changed, added, or removed therefrom to implement new or modified virtual operations using the sequence controller 910. If sequencer state table files 924, 926, 928 are created outside of memory 920, moreover, such files may be easily downloaded to a data store accessible by the processing component 912. In this regard, virtual system operators or service personnel may configure the sequence controller 910 and hence an entire virtual system from a remote location, according to the general inventive concepts, where the state table files 924, 926, 928 can be downloaded via the network 930 and other networks operationally connected thereto, including LANS, WANS, Internet connections, etc. Furthermore, it is noted that the elements of state table file entries can be any tags, strings, pointers, addresses, etc. that provide an indication of instructions, routines, numeric values, states, or actions that can be understood by processor 912 when executing the sequence control program 922. Thus, sequence configuration tool 929 (FIG. 10) can be any suitable hardware, software, firmware, or combinations thereof that can obtain the elements and logic of a virtual sequence and create a state table file 924, 926, 928 and entries thereof, and which can then be used in performing a virtual operation.

An exemplary embodiment of a virtual sequence including various welder (operator) and non-welder operations is diagrammatically represented in FIG. 13. In FIG. 13, at operation 1310, the virtual sequencer begins operation and can instruct the operator to enter the operator's identification number, proper part identification number, assembly identification number, etc. The virtual sequencer may also set the virtual welding equipment to use weld schedule A (operation 1320) and instruct the operator to virtually perform welds #1, #2, and #3. Then, the operator virtually performs welds #1, #2, and #3 using weld schedule A (operations 1322, 1324, and 1326). Next, the virtual sequencer sets the virtual welding equipment to use weld schedule B (operation 1330) and instructs the operator to perform weld #4. Then, the operator performs weld #4 using weld schedule B (operations 1332). After completion of weld schedule B, the virtual sequencer sets the virtual welding equipment to use weld schedule C (operation 1350) and instructs the operator to perform welds #5 and #6 and to visually inspect the part. Then, the operator performs welds #5 and #6 (operations 1352, and 1354) using weld schedule C and inspects the completed part or assembly to confirm that it is correct (operation 1360). This inspection may include dimensional verification, visual defect confirmation, or any other type of check that might be needed. Further, operation 1360 may include a requirement that the operator affirmatively indicate that the inspection is complete, such as by pressing an “OK” button, before it is possible to proceed to the next operation. Lastly, the virtual sequencer indicates that the virtual welding operation is at an end (operation 1370) and re-sets for the next operation. Data, including production data, can be gathered during all operations.

Accordingly, as noted above, the sequencing and scheduling of virtual welding operations is completed, or otherwise facilitated, by the sequencer, simulating the real-world welding station. Other operations automatically performed by the virtual sequencer could include, for example, changing the position of a fixture, actuating operational devices, displaying visual aids, controlling audible and visual indicators, verifying certain checks, etc. Other operations directed by the virtual sequencer for the welder operator could include, for example, retrieving a sample part, entering a sample part ID, placing the sample part in a fixture, actuating fixture clamps, performing a test, etc.

The virtual sequencer may select and implement a new function, such as the selection and implementation of weld schedules A, B and C shown in FIG. 13, based upon various variables or inputs. For example, the virtual sequencer may simply select new weld schedules based upon a monitoring of elapsed time since the beginning of the welding operations or since the cessation of welding (such as the time after weld #3 in FIG. 13 above). Alternatively, the virtual sequencer may monitor the actions of the operator, compare the actions to the identified sequence of welds, and select new weld schedules appropriately.

Still further, various combinations of these methods, or any other effective method, may be implemented, as long as the end effect is to simulate the real-world sequence and environment in the real-world weld station. By way of example, and not by way of limitation, the following real-world functions may be simulated in the virtual weld station and included in the virtual sequence.

A Quality Check function requires that a quality check of the weld be performed (either during welding or after the weld is completed) before allowing the job sequence to continue. The quality check can monitor various virtual welding parameters and can pause the welding operation and alert the operator if an abnormality is detected. An example of a welding parameter measurable by this function would be arc data.

Another exemplary function is a Repeat function. This function would instruct the operator to repeat a particular virtual weld or weld sequence. An example of the use of this function includes when the Quality Check function shows an abnormality, or when multiple instances of the same weld are required.

Another exemplary function is a Notify Welder function, which communicates information to the welder. This function would display information, give an audible signal, or communicate with the welder by some other means. Examples of use of this function include an indication to the operator that he is free to begin virtual welding or an indication that the operator should check some portion of the welded part for quality purposes.

Another exemplary function is an Enter Job Information function. This function will require the welder to enter information, such as the sample part serial number, a personal ID number, or other special conditions before the virtual sequencer can continue. This information could also be read from a sample part or inventory tag itself through RFID, bar code scanning, or the like. The virtual sequencer could then utilize the entered information for the virtual welding operations. An example of the use of this function would be as a predicate to the entire virtual welding operation, so as to indicate to the virtual sequencer which schedules and/or sequences should be selected.

Another exemplary function is a Job Report function. This function will create a report on the virtual welding job, which could include information such as: the number of virtual welds performed, total and individual arc timing, sequence interruptions, errors, faults, wire usage, arc data, and the like. An example of the use of this function would be to report to a manufacturing quality department on the efficiency and quality of the virtual processes.

Another exemplary function is a System Check function. This function will establish whether the virtual welding job can continue and could monitor such parameters as: wire supply, gas supply, time left in the shift (as compared to the required time to finish the job), and the like. The function could then determine whether the parameters indicate that there is enough time and/or material for the virtual welding job to continue. This function simulates efforts to prevent down-time due to material depletion and would prevent work-in-process assemblies from being delayed, which can lead to quality problems due to thermal and scheduling issues.

Further, as mentioned above, the virtual sequencer may select and implement a new function, based upon various variables or inputs. These variables and inputs are not particularly limited and can even be another function. For example, another exemplary function compatible with the virtual sequencer is a Perform Welding Operation function. This function is designed to detect the virtual welding performed by the operator and to report that welding so that the virtual sequencer can determine whether to proceed with further operations. For example, this function can operate by starting when the operator pulls the trigger to start the virtual welding operation and finishing when the operator releases the trigger after the virtual welding is complete, or after a predetermined period of time has lapsed. This function could end when the trigger is released or it could be configured to automatically turn off after a period of time, a quantity of wire, or an amount of energy is delivered. This function may be used to determine when to select a new function, such as a new weld schedule, as discussed above.

Still further, various semi-automatic and/or robotic work cells can be integrated together on a single network, and the sequencing of virtual welding steps at a single work-cell can be fully integrated into a virtual complete production schedule, which itself can be modified as needed to track variations in the virtual production schedule. Sequencing and/or scheduling information can also be stored in a database, be stored by date as archival information, and be accessed to provide various virtual production reports.

The exemplary virtual weld station embodiments described above and in the figures, including the exemplary virtual sequencer embodiments, can be used for a variety of training and operational optimization techniques, including lesson plans based on the following procedures. Production monitoring data may be gathered, compared, and manipulated in one or more common or separate databases from both virtual and real-world operations.

For example, FIG. 14 is a flow chart illustrating an exemplary training routine. An operator can perform virtual weld station operations before proceeding to real-world welding operations.

FIG. 15 is a flow chart illustrating an exemplary training routine using a virtual score. In this embodiment, the operator must achieve a certain score before proceeding to operate in the real-world weld station.

FIG. 16 is a flow chart illustrating an exemplary hiring process using a virtual performance measure. In this embodiment, the applicant (operator) must achieve a certain performance using the virtual weld station to be hired.

FIG. 17 is a flow chart illustrating an exemplary optimization routine using a virtual weld station. In this embodiment, the virtual weld station is used to optimize some aspect of the proposed sequence of operations. The virtual operations are modified until one or more aspects are acceptable (e.g., exceed some predetermined threshold or satisfy one or more quality parameters). Then, the virtual sequence is used as the real-world sequence.

FIG. 18 is a flow chart illustrating an exemplary training routine using a virtual score and a real-world score. In this embodiment, the operator must achieve a certain score before proceeding to operate in the real-world weld station. Then, a real-world sequencer (e.g., Lincoln Electric's Weld Sequencer) is used by the same operator on the same operation, and a real-world score is determined.

FIG. 19 is another flow chart illustrating an exemplary training routine using a virtual score and a real-world score. In this embodiment, the operator must achieve a certain score before proceeding to operate in the real-world weld station. Then, a real-world score is determined, and if the real-world score falls below a threshold, the operator can be further trained using the virtual weld station.

FIG. 20 is another flow chart illustrating a routine using a virtual score and a real-world score to determine how well the virtual station predicts real-world performance. In this embodiment, the virtual and real-world performance scores are compared to determine how well the virtual simulation predicts the real-world performance. If the correlation is not sufficient, the virtual simulation may be modified.

As can be seen, the virtual weld station and virtual sequencer can be used to gather and store a wealth of data that can be used to calculate and ultimately increase productivity. This data can be stored in a data “cloud” and then accessed for analysis and manipulation. The virtual sequencer can monitor and instruct the user to prevent missing welds, missing welding steps, missing other operations, excessive use of welding consumables, and other undesirable activities. The virtual sequencer can also be used to train users in the proper time for accomplishing or completing various welding or non-welding steps on a particular assembly. The virtual sequencer also leads to a consistent process order for making a particular weldment assembly. The virtual sequencer also reduces training time and scrap. The number of times each user had to be trained on certain assemblies to flag problematic parts for a particular user can also be determined. All of these items lead to increased productivity and less waste of time and resources.

While the general inventive concepts have been illustrated by the description of various embodiments thereof, and while the embodiments have been described in some detail, it is not the intention of the applicant to restrict, or in any way limit, the scope of the appended claims to such detail. Additional advantages and modifications will be readily apparent to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details, representative apparatus and methods, and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of the applicant's general inventive concepts. 

1. A virtual welding system comprising: a logic processor based subsystem operable to execute coded instructions for generating an interactive welding environment that emulates welding activity on a virtual weld joint defined by at least one of a welding coupon and a sample part; a virtual sequence controller operatively connected to the logic processor based subsystem for implementing a virtual sequence; displaying means operatively connected to the logic processor based subsystem for visually depicting the interactive welding environment including the virtual weld joint; an input device for performing virtual welding activity on the virtual weld joint in real time; and a spatial tracker comprising one or more sensors adapted to track movement of the input device in real time for communicating data about the movement of the input device to the logic processor based subsystem.
 2. The virtual welding system of claim 1, further comprising a user interface for a user to provide input to the virtual welding system.
 3. The virtual welding system of claim 1, wherein the logic processor based subsystem is housed within a simulated welding console that is sized and shaped to approximate a welding power source.
 4. The virtual welding system of claim 1, wherein the virtual sequence controller comprises a microprocessor, a sequence control program, and a memory, and wherein the memory stores one or more state table files.
 5. The virtual welding system of claim 4, wherein the virtual sequence is defined by at least one of the state table files.
 6. The virtual welding system of claim 4, wherein a user selects one of the state table files based on a task to be performed; and wherein the task is production of a complete virtual assembly.
 7. The virtual welding system of claim 1, wherein the virtual sequence includes a plurality of operations to be performed in order, each operation intended to achieve a particular state.
 8. The virtual welding system of claim 7, wherein at least one of the operations is a manual operation to be performed by the user.
 9. The virtual welding system of claim 8, wherein the manual operation is one of providing user information, retrieving a part, providing part information, placing a part, securing a part, and providing assembly information.
 10. The virtual welding system of claim 8, further comprising a virtual sequence display means; wherein the virtual sequence display means displays information on the manual operation.
 11. The virtual welding system of claim 7, wherein at least one of the operations is an automatic operation to be performed by the virtual welding system.
 12. The virtual welding system of claim 11, wherein the automatic operation is one of specifying a weld process, specifying a gas type, specifying a gas flow rate, specifying a stick electrode type, specifying a flux cored wire type, specifying a wire feed speed, specifying a voltage level, specifying an amperage, specifying a polarity, and specifying a background environment for the interactive welding environment.
 13. The virtual welding system of claim 7, wherein each state is associated with a condition.
 14. The virtual welding system of claim 13, wherein the sequence controller performs an action if the condition is not met.
 15. The virtual welding system of claim 1, wherein the displaying means is a face-mounted display.
 16. The virtual welding system of claim 1, further comprising a support structure.
 17. The virtual welding system of claim 16, wherein the support structure is a stand comprising a base, a vertical post, an adjustable table, and an adjustable arm.
 18. The virtual welding system of claim 16, wherein the support structure is an assembly fixture for holding the sample part.
 19. The virtual welding system of claim 1, further comprising means for collecting and storing welding and operational data from the virtual sequence controller.
 20. The virtual welding system of claim 1, further comprising means for assigning a quality score to the virtual welding activity. 